Nozzle cover and mold adjustments

- codpiece for the nozzle;
- shortened molds for single component silicone, namely
  Abro "The Gasket Maker" Red ("abro" flag in stuff.scad).

Signed-off-by: Ivan Kokshaysky <ink@rc.ru>

3 files changed, 57 insertions, 14 deletions

diff --git a/e3dv6.scad b/e3dv6.scad
index 902eb52..9b74f8a 100644
--- a/e3dv6.scad
+++ b/e3dv6.scad
@@ -27,8 +27,17 @@ the_w = ss + max(c_tw,ts_t)+hb_w+c_t + ss;
 the_l = ss + hb_l + ss;
 the_h = sv + hb_h + ss;
 
+/* Nozzle stuff */
+n_protrude = 0.4;	// nozzle tip protrusion from silicone
+n_h1 = 3.6;		// nozzle cone base from the heater body (minimal)
+n_cone_h = 2;		// nozzle cone height
+n_cone_d2 = 1;		// pad diameter of the 0.4 nozzle (works up to 0.6); see
+			// http://wiki.e3d-online.com/images/3/3a/V6-NOZZLE-ALL.pdf
+n_cone_d1 = n_cone_h * tan(40) * 2 + n_cone_d2;
+codpiece_h = n_h1 + n_cone_h - n_protrude;
+
 use <bubbles.scad>;
-module heatershape(bubbled=true) {
+module heatershape(bubbled=true, codpiece=false) {
  m = n_offset_l-hb_d/2;
  module topholes(h) {
   hull() {
@@ -46,15 +55,29 @@ module heatershape(bubbled=true) {
  translate([0,0,hb_h]) {
   // irrelevant, because we print upside-down: mo = m+max(c_t,c_tw)+ss; th=3*ss;
   mo = protrude/4; th = protrude/2;
-  translate([0,0,-1]) topholes(h=ss+protrude);
-  translate([0,0,ss+protrude-mo-th]) hull() {
-   topholes(h=layer_height);
-   translate([-c_tw-ss,-ss,mo])
-   cube(size=[the_w,the_l,th]);
-  }
+  translate([0,0,-1]) topholes(h=ss+th);
+  if (!abro)
+   translate([0,0,ss+protrude-mo-th]) hull() {
+    topholes(h=layer_height);
+    translate([-c_tw-ss,-ss,mo])
+     cube(size=[the_w,the_l,th]);
+   }
+  else
+   translate([-c_tw-ss,-ss,ss])
+    cube(size=[the_w,the_l,th]);
  }
  // nozzle
- translate([n_offset_w,n_offset_l,1]) mirror([0,0,1]) cylinder(d=n_d,h=sv+1,$fn=24);
+ translate([n_offset_w,n_offset_l,1]) mirror([0,0,1])
+  if (codpiece) {
+   mc_d2 = n_cone_d2 + n_protrude * tan(40) * 2;
+   intersection() {
+    cylinder(d = n_d, h = n_h1 + 1 + epsilon, $fn=24);
+    cylinder(d1 = n_d * 2, d2 = 0, h = n_h1 * 2 + 1, $fn=24);
+   }
+   translate([0, 0, n_h1 + 1])
+    cylinder(h = n_cone_h - n_protrude, d1 = n_cone_d1, d2 = mc_d2, $fn = 32);
+  } else
+   cylinder(d=n_d,h=sv+1,$fn=24);
  // heater screw
  translate([hs_offset_w,hs_offset_l,1]) mirror([0,0,1]) cylinder(d=hs_d,h=hs_t+1,$fn=24);
  // thermistor screw
@@ -89,11 +112,27 @@ echo("volume",vol);
 use <view.scad>;
 use <mold.scad>;
 
-view="*";
+codpiece = true;
+view="inner";
 
 view(view=view,volume=vol) {
- mold(size=[the_w,the_l,the_h],s=ms,v_protrude=protrude,introffset=ss+c_offset_l);
- translate([ms+c_tw+ss,ms+ss,ms+sv]) heatershape();
- translate([ms+epsilon,ms+epsilon,ms+epsilon]) cube(size=[the_w-2*epsilon,the_l-2*epsilon,the_h-2*epsilon]);
+ cp_h = codpiece ? codpiece_h - sv : 0;
+ prt = abro ? protrude / 2 : protrude;
+ difference() {
+  union() {
+   mold(size=[the_w,the_l,the_h],s=ms,v_protrude=prt,introffset=ss+c_offset_l);
+   if (codpiece)
+    translate([0, 0, -cp_h])
+     cube([the_w + ms * 2, the_l + ms * 2, cp_h + epsilon]);
+  }
+  if (codpiece)
+   translate([ms + c_tw + ss + n_offset_w, ms + ss + n_offset_l, ms]) {
+    scale([1, 1, codpiece_h / (n_d + 2)])
+     sphere(d = n_d + 2, $fn = 64);
+   }
+ }
+ translate([ms+c_tw+ss,ms+ss,ms+sv]) heatershape(true, codpiece);
+ translate([ms+epsilon,ms+epsilon,ms+epsilon - cp_h])
+  cube(size=[the_w-2*epsilon,the_l-2*epsilon,the_h-2*epsilon + cp_h]);
 }
 /* vim:set ai sw=1: */
diff --git a/stuff.scad b/stuff.scad
index 26fb39f..922e702 100644
--- a/stuff.scad
+++ b/stuff.scad
@@ -4,3 +4,5 @@ epsilon = .01;
 protrude=10;				// distance to protrude vertically
 ss=1;			                // minimum silicone shell thickness
 ms=1;					// mold shell thickness
+
+abro = 1;				// single component silicone
diff --git a/view.scad b/view.scad
index e3dcbee..cc996d6 100644
--- a/view.scad
+++ b/view.scad
@@ -1,3 +1,4 @@
+include <stuff.scad>;
 use <mixing.scad>;
 
 /**
@@ -26,8 +27,9 @@ module view(view,volume) {
  }else{
   cou() children(0); cin() children(1);
   csi() children(2);
-  translate([-mixing_size(volume=volume)[1]*2,0]) rotate([0,0,90])
-  cmx() mixing(volume=volume,what="altogethernow");
+  if (!abro)
+   translate([-mixing_size(volume=volume)[1]*2,0]) rotate([0,0,90])
+    cmx() mixing(volume=volume,what="altogethernow");
  }
 }
 /* vim:set ai sw=1: */